Patents by Inventor Carl R. Deckard
Carl R. Deckard has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 10695979Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.Type: GrantFiled: August 28, 2019Date of Patent: June 30, 2020Assignee: STRATASYS, INC.Inventors: James K. Mikulak, Carl R. Deckard, Robert L. Zinniel
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Publication number: 20190381728Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.Type: ApplicationFiled: August 28, 2019Publication date: December 19, 2019Inventors: James K. Mikulak, Carl R. Deckard, Robert L. Zinniel
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Patent number: 10493695Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.Type: GrantFiled: July 25, 2017Date of Patent: December 3, 2019Assignee: STRATASYS, INC.Inventors: James K. Mikulak, Carl R. Deckard, Robert L. Zinniel
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Publication number: 20190240869Abstract: A consumable polymeric based powder mixture may include a plurality of polymeric based particles that have a unitary construction. At least about 80% of the plurality of polymeric based particles may further have a generally cylindrical shape. The plurality of polymeric based particles may further have a particle length distribution span (PLDS) of not greater than about 1.2, where PLDS is equal to (L80?L20)/L50.Type: ApplicationFiled: April 16, 2019Publication date: August 8, 2019Inventors: Vikram DEVARAJ, James K. MIKULAK, Carl R. DECKARD
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Patent number: 10307935Abstract: A consumable polymeric based powder mixture may include a plurality of polymeric based particles that have a unitary construction. At least about 80% of the plurality of polymeric based particles may further have a generally cylindrical shape. The plurality of polymeric based particles may further have a particle length distribution span (PLDS) of not greater than about 1.2, where PLDS is equal to (L80?L20)/L50.Type: GrantFiled: December 21, 2016Date of Patent: June 4, 2019Assignee: Structured Polymers, Inc.Inventors: Vikram Devaraj, James K. Mikulak, Carl R. Deckard
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Publication number: 20180281232Abstract: A consumable polymeric based powder mixture may include a plurality of polymeric based particles that have a unitary construction. At least about 80% of the plurality of polymeric based particles may further have a generally cylindrical shape. The plurality of polymeric based particles may further have a particle length distribution span (PLDS) of not greater than about 1.2, where PLDS is equal to (L80?L20)/L50.Type: ApplicationFiled: December 21, 2016Publication date: October 4, 2018Inventors: Vikram DEVARAJ, James K. MIKULAK, Carl R. DECKARD
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Publication number: 20170320266Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.Type: ApplicationFiled: July 25, 2017Publication date: November 9, 2017Inventors: James K. Mikulak, Carl R. Deckard, Robert L. Zinniel
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Patent number: 9738031Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.Type: GrantFiled: April 3, 2013Date of Patent: August 22, 2017Assignee: Stratasys, Inc.Inventors: James K. Mikulak, Carl R. Deckard, Robert L. Zinniel
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Patent number: 8920697Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.Type: GrantFiled: March 14, 2012Date of Patent: December 30, 2014Assignee: Stratasys, Inc.Inventors: James K. Mikulak, Carl R. Deckard, Robert L. Zinniel
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Patent number: 8801990Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a first portion of a first semi-crystalline polymeric material, and a second portion of a second semi-crystalline polymeric material, and where the second semi-crystalline polymeric material has a crystallization temperature that is greater than a crystallization temperature of the first semi-crystalline polymeric material.Type: GrantFiled: September 15, 2011Date of Patent: August 12, 2014Assignee: Stratasys, Inc.Inventors: James K. Mikulak, Carl R. Deckard
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Publication number: 20120231225Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.Type: ApplicationFiled: March 14, 2012Publication date: September 13, 2012Applicant: STRATASYS, INC.Inventors: James K. Mikulak, Carl R. Deckard, Robert L. Zinniel
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Publication number: 20120070619Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a first portion of a first semi-crystalline polymeric material, and a second portion of a second semi-crystalline polymeric material, and where the second semi-crystalline polymeric material has a crystallization temperature that is greater than a crystallization temperature of the first semi-crystalline polymeric material.Type: ApplicationFiled: September 15, 2011Publication date: March 22, 2012Applicant: STRATASYS, INC.Inventors: James K. Mikulak, Carl R. Deckard
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Patent number: 5639070Abstract: A method and apparatus for selectively sintering a layer of powder to produce a part as a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. Preferably, the powder dispensing mechanism includes a drum which is moved horizontally across the target area and counter-rotated to smooth and distribute the powder in an even layer across the target area. A downdraft system provides controlled temperature air flow through the target area to moderate powder temperature during sintering.Type: GrantFiled: June 7, 1995Date of Patent: June 17, 1997Assignee: Board of Regents, The University of Texas SystemInventor: Carl R. Deckard
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Patent number: 5616294Abstract: A method and apparatus for selectively sintering a layer of powder to produce a part as a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. Preferably, the powder dispensing mechanism includes a drum which is moved horizontally across the target area and counter-rotated to smooth and distribute the powder in an even layer across the target area. A downdraft system provides controlled temperature air flow through the target area to moderate powder temperature during sintering.Type: GrantFiled: June 7, 1995Date of Patent: April 1, 1997Assignee: Board of Regents, The University of Texas SystemInventor: Carl R. Deckard
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Patent number: 5597589Abstract: An apparatus for selectively sintering a layer of powder to produce a part made from a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. Preferably, the powder dispensing mechanism includes a drum which is moved horizontally across the target area and counter-rotated to smooth and distribute the powder in an even layer across the target area. A downdraft system provides controlled temperature air flow through the target area to moderate powder temperature during sintering.Type: GrantFiled: May 31, 1994Date of Patent: January 28, 1997Assignee: Board of Regents, The University of Texas SystemInventor: Carl R. Deckard
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Patent number: 5382308Abstract: A method and apparatus for selectively sintering a layer of powder to produce a part comprising a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. Preferably, the powder comprises a plurality of materials having different dissociation or bonding temperatures. The powder preferably comprises blended or coated materials.Type: GrantFiled: March 21, 1994Date of Patent: January 17, 1995Assignee: Board of Regents, The University of Texas SystemInventors: David L. Bourell, Harris L. Marcus, Joel W. Barlow, Joseph J. Beaman, Carl R. Deckard
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Patent number: 5316580Abstract: A method and apparatus for selectively sintering a layer of powder to produce a part comprising a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. Preferably, the powder dispensing mechanism includes a drum which is moved horizontally across the target area and counter-rotated to smooth and distribute the powder in an even layer across the target area. A downdraft system provides controlled temperature air flow through the target area to moderate powder temperature during sintering.Type: GrantFiled: July 10, 1992Date of Patent: May 31, 1994Assignee: Board of Regents, The University of Texas SystemInventor: Carl R. Deckard
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Patent number: 5296062Abstract: A method and apparatus for selectively sintering a layer of powder to produce a part comprising a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. Preferably, the powder comprises a plurality of materials having different dissociation or bonding temperatures. The powder preferably comprises blended or coated materials.Type: GrantFiled: September 25, 1992Date of Patent: March 22, 1994Assignee: The Board of Regents, The University of Texas SystemInventors: David L. Bourell, Harris L. Marcus, Joel W. Barlow, Joseph L. Beaman, Carl R. Deckard
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Patent number: 5252264Abstract: An apparatus and method for producing parts by fusing selected portions of a layer of powder at a target area, including the systems for delivering the powder to the target area, is disclosed. Multiple powder pistons are included in the apparatus, each of which lift a volume of powder above a surface in an alternating manner relative to one another. Powder delivery begins by the lifting of a volume of powder at a first location on one side of the target area. A counter-rotating roller moves across the lifted powder, distributes it over the target area, and rests beyond a second powder lifting location on the other side of the target area. Portions of the powder layer are then fused at the target area according to a cross-section of the part to be produced, and is followed by lowering a part cylinder at the target area in order to accept the next layer of powder.Type: GrantFiled: November 8, 1991Date of Patent: October 12, 1993Assignee: DTM CorporationInventors: Paul F. Forderhase, Carl R. Deckard, Jack M. Klein
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Patent number: 5155324Abstract: An apparatus and method for producing parts by selective laser sintering are disclosed. The disclosed method selectively sinters a first layer of heat-fusible powder by directing a laser beam so that it scans the first layer in a first direction to sinter a first cross-section of the part. A second layer of the heat-fusible powder is then disposed over the first layer, and the next cross-section of the part is selectively sintered by the laser being scanned in a different direction from the first direction, for example in a direction perpendicular to the first direction. The cross-scanning resulting from scanning in different directions provides parts with structural strength which is not dependent upon orientation, with more uniform surfaces and textures, and with reduced distortion. In addition, each of the layers may have its outlined traced prior to the scanning, to further define the edges of the cross-section.Type: GrantFiled: November 9, 1990Date of Patent: October 13, 1992Inventors: Carl R. Deckard, Joseph J. Beaman, James F. Darrah